Thermally Formed Three-Dimensional Mesh Fabric

ABSTRACT

A thermally formed three-dimensional mesh fabric comprises a flexible three dimensional permeable sheet and a thermally formed cover. The flexible three dimensional permeable sheet has a surface and a softening temperature. The thermally formed cover is applied to at least a portion of the surface of the three dimensional permeable sheet, is low-temperature thermoplastic polyester and has a softening temperature lower than that of the three dimensional permeable sheet. Thus, thermal forming three-dimensional mesh fabric is permeable, lightweight and has good support and is suitable for applications such as splints, plaster bandages and safety protectors.

FIELD OF THE INVENTION

The present invention relates to a thermally formed three-dimensional mesh fabric and more particularly to a fabric that can be shaped by increasing temperature and memorizing a shape after cooling.

DESCRIPTION OF THE RELATED ART

A splint is a medical device that immobilizes and supports an injured body part (usually a fractured or contused limb) and prevents the limb from incurring secondary damage resulting from improper extension or movement of the limb.

Various types and materials are used for conventional splints, such as plaster, preshaped plastic fastening components, metal or rigid frames. In the past, injured limbs have been often immobilized by wrapping gauze soaked in plaster around it and allowing the plaster to harden. However, using plaster is a delicate process and takes a long time to harden. In addition, a plaster splint is heavy, cannot breathe or be temporarily removed and may affect a patient adversely. For example, a patient with sensitive skin may develop sores that result in secondary infection or damage.

Other kinds of conventional splints may be lighter than plaster splints but do not breath. For example, preshaped plastic components may be lightweight but do not breath. A rigid frame splint is more permeable but provides less protection because it does not completely cover and support an injured limb.

SUMMARY OF THE INVENTION

The primary objective of the present invention is to provide a thermally formed three-dimensional mesh fabric that overcomes problems with rigid materials such as being heavy and impermeable or not providing sufficient support and protection.

The thermally formed three-dimensional mesh fabric in accordance with the present invention comprises a flexible three dimensional permeable sheet and a thermally formed cover. The three dimensional permeable sheet has a surface and a softening temperature, is a fiber fabric having one or more layers of mesh and is selected from a group consisting of polylactid (PLA), poly(butylene adipate (PBA), poly(butylene succinate (PBS) and polycaprolactone (PCL).

The thermally formed cover is applied to at least part of the surface of the three dimensional permeable sheet, may be applied to the entire surface by dip coating or lamination coating and may be attached to the first and second meshes by spraying, coating or bonding and has multiple through holes, is low-temperature thermoplastic polyester has a softening temperature and comprises at least one additive. The softening temperature is lower than that of the three dimensional permeable sheet. The additive is inorganic or organic. The inorganic additive is mica, clay, zirconium oxide, silver, carbon black, calcium carbonate or glass fiber.

The three dimensional permeable sheet is thermoplastic fiber selected from the group consisting of PA (poly(dimer acid-co-alkyl polyamine)), PET (polyethylene terephthalate), PP (polypropene), PVC (polyvinyl Chloride, and LCP (liquid crystal polyester) and has a mesh layer. The mesh layer comprises a first mesh, a second mesh and a connecting network. The connecting network joins the first and second meshes and comprises multiple flexible and elastic filaments. Each filament is connected to the first and second meshes by weaving.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective schematic view of an embodiment of a thermal forming three-dimensional mesh fabric in accordance with the present invention in partial section;

FIG. 2 is a top view of the embodiment of the thermal forming three-dimensional mesh fabric in FIG. 1 in partial section;

FIG. 3 is a cross-sectional side view of the embodiment of the thermal forming three-dimensional mesh fabric in FIG. 1 in partial section;

FIG. 4 is an enlarged cross-sectional side view of the embodiment of the thermal forming three-dimensional mesh fabric in FIG. 1 in partial section;

FIG. 5 is a cross-sectional side view of another embodiment of a thermal forming three-dimensional mesh fabric in accordance with the present invention in partial section; and

FIG. 6 is an operational side view of a splint with an embodiment of a thermal forming three-dimensional mesh fabric in accordance with the present invention; and

FIG. 6 a is an enlarged side view of the embodiment of a thermal forming three-dimensional mesh fabric in FIG. 6.

DETAILED DESCRIPTION OF THE INVENTION

With reference to FIGS. 1 to 4, a thermally formed three-dimensional mesh fabric in accordance with the present invention may be cut to a suitable shape and size, is heated to soften the thermally formed fabric, is mounted immediately around an injured limb, is allowed to cool and harden and comprises a three dimensional permeable sheet (10) and a thermally formed cover (20).

The three dimensional permeable sheet (10) is flexible, is made by weaving and mixing fibers to form a three-dimensional mesh fabric has a surface and a softening temperature and may be thermoplastic fiber selected from a group consisting of poly(dimer acid-co-alkyl polyamine) (PA), polyethylene terephthalate (PET), polypropene (PP), polyvinyl chloride (PVC), liquid crystal polyester (LCP) and the like. The three dimensional permeable sheet (10) may be a fiber fabric having one or more mesh layers. A mesh layer may comprise a first mesh (12), a second mesh (14) and a connecting network (16). The first mesh (12) is permeable. The second mesh (14) is permeable. The connecting network (16) joins the first and second meshes (12, 14) and comprises multiple flexible and elastic filaments (161). Each filament (161) is connected to the first and second meshes (12, 14) by weaving and forms a loose, permeable and flexible support.

With further reference to FIG. 5, the thermally formed cover (20) is applied to part or all of the surface of the flexible three dimensional permeable sheet (10) to add support and protection for an injured limb, may be applied to the first mesh (12), the second mesh (14) or both, is low-temperature thermoplastic polyester, may be polylactid (PLA), poly(butylene adipate) (PBA), poly(butylene succinate) (PBS), polycaprolactone (PCL) or mixtures of the foregoing and may be mixed and blended with at least one optional additive. The softening temperature is lower than that of the three dimensional permeable sheet (10) and may be thermally formed and shaped when the thermally formed cover's (20) temperature is greater than the softening temperature. For example, the softening temperature may be 50-90° C. The softening temperatures of the three dimensional permeable sheet (10) and the thermally formed cover (20) are different to ensure that heating the thermally formed cover (20) will not damage layers of the three dimensional permeable sheet (10). The optional additive adjusts the softening temperature, increases strength, provides other characteristics such as being antibacterial or mildew proof and may be organic or inorganic. An inorganic optional additive may have a far infrared emissive, antibacterial, mildew proof or strengthening characteristics and may be mica, clay, zirconium oxide, silver, carbon black, calcium carbonate, or glass fiber. The thermally formed cover (20) may be applied to the first and second meshes (12, 14) and the filaments (161) of the connecting network (16) during manufacturing by heating and melting the thermally formed cover (20) or dissolving the thermally formed cover (20) in a solvent and dipping or laminating the three dimensional permeable sheet (10) with the thermally formed cover (20).

However, the thermally formed cover (20) may not be coated evenly on all or most of the three dimensional permeable sheet (10) because thickness of the thermally formed cover (20) is difficult to control when dip coating, and the thermally formed cover (20) may be attached to adjacent filaments or fibers. However, the uneven thickness will not affect gas permeability, thermal forming and shape memory properties.

The thermally formed cover (20) can also be directly attached to surfaces of the first mesh (12), second mesh (14) or both by spraying, coating or bonding to provide high support and strength. Moreover, to enhance the gas permeability of the thermally formed cover (20A), it may have multiple through holes (21).

With further reference to FIGS. 6 and 6 a, to facilitate attaching the thermally formed three-dimensional mesh fabric to an injured limb or body part, the thermally formed three-dimensional mesh fabric may be precut out to form a permeable thermally formed splint (30). The permeable thermally formed splint (30) comprises multiple segments of thermally formed three-dimensional mesh fabric (31) in accordance with the present invention and multiple fasteners (32).

The segments of thermally formed three-dimensional mesh fabric (31) have an outer surface and are cut to fit and cover a limb. When the permeable thermally formed splint (30) is applied, it is heated, deformed, and attached to the limb so that cutting and sizing is not necessary.

The fasteners (32) are mounted on outer surfaces of the thermally formed three-dimensional mesh fabric (31) and may be, but are not limited to, belts or buckles. For example, the fasteners (32) can be a buckle set, including a buckle mount and a buckle. The buckle mount is mounted securely on the outer surface of the thermally formed three-dimensional mesh fabric (31) and is clipped detachably to a buckle mount. When the permeable thermally formed splint (30) is used and covers the limb, the buckle is clipped to the buckle mount. Thus, the thermally formed three-dimensional mesh fabric (31) can be fastened more closely to an injured limb.

Moreover, embodiments of the present invention can also be applied in other fields, such as mattresses, safety protectors (e.g. helmet liners, knee, elbow or other body guards) or plaster bandage. Because the embodiments of the present invention are highly permeable and can be thermally formed, the embodiments of the present invention are suitable as inner liners of bicycle and motorcycle helmets which need good ventilation. The embodiments of the present invention can be preformed to a hemispherical shape for fitting a human head and then mounted in a hard cap to form a helmet. Thus, the helmet is well-ventilated and can provide comfortable feelings for bicycle or motorcycle riders.

When the embodiments of the present invention are used for knee or elbow guards of, they can be shaped according to a user's knee or elbow size and then mounted into a rigid outer shell with a joint mechanism. Thus, the knee or elbow guards can provide good protective effect.

Embodiments of the thermally formed three-dimensional mesh fabric in accordance with the present invention are suitable for many applications and have high market potential and value. 

1. A thermally formed three-dimensional mesh fabric comprising a three dimensional permeable sheet being flexible and having a surface and a softening temperature; and a thermally formed cover being applied to at least part of the surface of the flexible three dimensional permeable sheet, being low-temperature thermoplastic polyester and having a softening temperature lower than that of the three dimensional permeable sheet.
 2. The thermally formed three-dimensional mesh fabric as claimed in claim 1, wherein the three dimensional permeable sheet is thermoplastic fiber selected from a group consisting of polylactid (PLA), poly(butylene adipate) (PBA), poly(butylene succinate) (PBS) and polycaprolactone (PCL).
 3. The thermally formed three-dimensional mesh fabric as claimed in claim 2, wherein the three dimensional permeable sheet is a fiber fabric having one or more mesh layers; and the thermally formed cover comprises at least one additive and the additive is inorganic.
 4. The thermally formed three-dimensional mesh fabric as claimed in claim 3, wherein the three dimensional permeable sheet has a mesh layer comprising a first mesh, a second mesh and a connecting network joining the first and second meshes; and the connecting network comprises multiple flexible and elastic filaments, and each filament is connected to the first and second meshes by weaving.
 5. The thermally formed three-dimensional mesh fabric as claimed in claim 4, wherein the thermally formed cover is applied to the entire surface of the three dimensional permeable sheet by dip coating or lamination.
 6. The thermally formed three-dimensional mesh fabric as claimed in claim 1, wherein the three dimensional permeable sheet has a mesh layer comprising a first mesh, a second mesh and a connecting network joining the first and second meshes; and the connecting network comprises multiple flexible and elastic filaments, and each filament is connected to the first and second meshes by weaving.
 7. The thermally formed three-dimensional mesh fabric as claimed in claim 6, wherein the thermally formed cover is attached to the first and second meshes by spraying, coating or bonding and has multiple through holes.
 8. The thermally formed three-dimensional mesh fabric as claimed in claim 7, wherein the three dimensional permeable sheet is thermoplastic fiber selected from a group consisting of poly(dimer acid-co-alkyl polyamine) (PA), polyethylene terephthalate (PET), polypropene (PP), polyvinyl chloride (PVC), and liquid crystal polyester (LCP).
 9. The thermally formed three-dimensional mesh fabric as claimed in claim 1, wherein the three dimensional permeable sheet is a fiber fabric having one or more mesh layers; and the thermally formed cover comprises at least one additive, and the additive is inorganic.
 10. The thermally formed three-dimensional mesh fabric as claimed in claim 9, wherein the three dimensional permeable sheet has a mesh layer comprising a first mesh, a second mesh and a connecting network joining the first and second meshes; and the connecting network comprises multiple flexible and elastic filaments, and each filament is connected to the first and second meshes by weaving.
 11. The thermally formed three-dimensional mesh fabric as claimed in claim 10, wherein the thermally formed cover is applied to the entire surface of the three dimensional permeable sheet by dip coating, or lamination.
 12. The thermally formed three-dimensional mesh fabric as claimed in claim 2, wherein the three dimensional permeable sheet has a mesh layer comprising a first mesh, a second mesh and a connecting network joining the first and second meshes; and the connecting network comprises multiple flexible and elastic filaments, and each filament is connected to the first and second meshes by weaving.
 13. The thermally formed three-dimensional mesh fabric as claimed in claim 12, wherein the thermally formed cover is attached to the first and second meshes by spraying, coating or bonding and has multiple through holes.
 14. The thermally formed three-dimensional mesh fabric as claimed in claim 3, wherein the inorganic additive is mica.
 15. The thermally formed three-dimensional mesh fabric as claimed in claim 3, wherein the inorganic additive is clay.
 16. The thermally formed three-dimensional mesh fabric as claimed in claim 3, wherein the inorganic additive is zirconium oxide.
 17. The thermally formed three-dimensional mesh fabric as claimed in claim 3, wherein the inorganic additive is silver.
 18. The thermally formed three-dimensional mesh fabric as claimed in claim 3, wherein the inorganic additive is carbon black.
 19. The thermally formed three-dimensional mesh fabric as claimed in claim 3, wherein the inorganic additive is calcium carbonate.
 20. The thermally formed three-dimensional mesh fabric as claimed in claim 3, wherein the inorganic additive is glass fiber. 